Composite-overwrapped pressure vessel system

Abstract

The pressure vessel system can include a pressure vessel and an optional jacket. However, the system 100 can additionally or alternatively include any other suitable set of components. The pressure vessel can include a liner, an optional composite overwrap, and/or any other suitable components. For example, the pressure vessel can be a composite overwrapped pressure vessel (COPV) with a metallic liner (e.g., alloyed aluminum). The pressure vessel system can function to store fluid (e.g., cryo-compressed hydrogen) within an interior chamber.

We claim: 
     
       1. A cryo-compression vessel comprising:
 an insulation layer; and 
 a composite overwrapped pressure vessel (COPV) encapsulated within the insulation layer and at least partially separated from the insulation layer by an interstitial gas chamber, the COPV comprising:
 a liner comprising a cylinder with a pair of ellipsoidal end caps formed as a unitary body from a metal alloy, the metal alloy comprising: greater than 92.0% aluminum by mass, greater than 2.0% copper by mass, greater than 0.2% manganese by mass, and less than 0.6% magnesium by mass; and 
 a composite overwrap structure encapsulating the metal liner, 
 
 wherein the COPV houses cryo-compressed hydrogen at a pressure above 100 bar and at a cryogenic temperature. 
 
     
     
       2. The cryo-compression vessel of  claim 1 , wherein the metal alloy comprises: between 92.0% and 96.8% aluminum by mass, between 2.0% and 6.5% copper by mass, and between 0.2% and 0.5% manganese by mass. 
     
     
       3. The cryo-compression vessel of  claim 2 , wherein the metal alloy comprises between 3.2% and 6.3% copper by mass. 
     
     
       4. The cryo-compression vessel of  claim 3 , wherein the metal alloy comprises between 0.2% and 0.6% magnesium by mass. 
     
     
       5. The cryo-compression vessel of  claim 1 , wherein the metal alloy comprises between 0.2% and 0.5% manganese by mass. 
     
     
       6. The cryo-compression vessel of  claim 1 , wherein the metal alloy is a non-weldable aluminum-copper alloy. 
     
     
       7. The cryo-compression vessel of  claim 1 , wherein the composite overwrap structure comprises carbon fiber. 
     
     
       8. The cryo-compression vessel of  claim 7 , wherein composite overwrap structure defines a first thickness between 0.125 inches and 2 inches, wherein the liner defines a second thickness between 0.05 inches and 0.5 inches. 
     
     
       9. The cryo-compression vessel of  claim 7 , wherein, at 77 Kelvin, an elastic modulus of the liner is less than an elastic modulus of the composite overwrap structure. 
     
     
       10. The cryo-compression vessel of  claim 1 , wherein the COPV is configured to house hydrogen gas at 350 bar with the interstitial gas chamber at a vacuum pressure. 
     
     
       11. The cryo-compression vessel of  claim 1 , wherein the unitary body comprises a cylinder with a pair of domed ends, wherein the cylinder comprises a Length-over-Diameter (L/D) ratio between 1.5 and 5. 
     
     
       12. The cryo-compression vessel of  claim 1 , wherein the liner is fluidly coupled to a pressurized interior of the COPV. 
     
     
       13. The cryo-compression vessel of  claim 1 , wherein the insulation layer comprises a structural enclosure and is substantially rigid, wherein the COPV is mechanically coupled to the structural enclosure. 
     
     
       14. The cryo-compression vessel of  claim 1 , wherein the unitary body is spin formed or flow formed. 
     
     
       15. A composite overwrapped pressure vessel (COPV) for storing cry-compressed hydrogen, the COPV comprising:
 a liner formed as a unitary body from an alloy, the alloy comprising: between 92.0% and 96.8% aluminum by mass, between 2.0% and 6.5% copper by mass, between 0.2% and 0.5% manganese by mass, wherein the alloy defines a fatigue crack growth rate exponent defined at 77 Kelvin of less than 3.25 inches per cycle within a linear elastic fatigue crack growth regime; and 
 a composite overwrap surrounding the liner. 
 
     
     
       16. The COPV of  claim 15 , wherein the alloy further comprises magnesium. 
     
     
       17. The COPV of  claim 15 , wherein the linear elastic fatigue crack growth regime is between the stress intensity factor (K) range defined by: 3 ksi√in<ΔK<30 ksi√in. 
     
     
       18. The COPV of  claim 15 , wherein the alloy defines a yield strength above 50 ksi, and a strain to failure above 15 percent. 
     
     
       19. The COPV of  claim 15 , wherein the alloy is pre-treated by a T6 Heat Treatment Process. 
     
     
       20. The COPV of  claim 15 , wherein the COPV defines a pair of necks at opposing ends of the COPV, wherein for each neck of the pair of necks, a respective mount supports the COPV at the respective neck.